Permeate adapter for multi-tube pressure vessel

ABSTRACT

A permeate adapter is provided. The permeate adapter may be used within a pressure vessel. The permeate adapter includes a front portion and an oppositely disposed back portion. The front portion includes a permeate opening for receiving an end of a permeate passage tube of a membrane cartridge and for being in fluid communication with a permeate reservoir. The front portion and the back portion each include one or more fluid openings. Fluid passageways are connected between the one or more front portion fluid openings and the back portion fluid openings. The fluid passageways receive an end of a membrane cartridge at the front portion. At the back portion, the fluid passageways are in fluid communication with a fluid reservoir adjacent the back portion of the permeate adapter.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Continuation of copending application Ser. No.11/906,262 filed Oct. 1, 2007, the contents of which are herebyincorporated by reference in its entirety.

FIELD

This technical disclosure relates generally to fluid separation and,more particularly, to fluid separation via multiple membrane cartridgesor modules disposed within a pressure vessel.

BACKGROUND

A variety of commercial processes rely on the use of fluid separationtechniques to separate one or more desirable fluid components from amixture. In particular, various such processes may involve theseparation of liquid mixtures, the separation of vapors or gases fromliquids, or the separation of intermingled gases.

The use of membranes for fluid separations has achieved increasedpopularity over other known separation techniques. Membranes, onceproduced into elements, are typically formed into modules or cartridges,e.g., a tube containing a plurality of membrane separation elements.Modules can be used singly or, more commonly, interconnected in seriesor parallel arrangements or arrays in the form of membrane skids.

One of the difficulties in building membrane skids is the need to ensurethat the permeate header lines up with the flange connections at the endof the membrane pressure tube. Increasing the number of modules in aninstallation increases the number of flange connections that mustproperly aligned with a permeate header thereby increasing thedifficulty of interconnecting individual modules.

In addition, a common problem associated with the use of spiral woundmembranes is that each module containing the membranes is typicallyrequired to be machined to a close tolerance to assure good pressureseals. As a result, the cost for each module can be significantlyincreased.

Further, each of the membrane modules loaded on an individual skidrequires some physical separation to accommodate installation of theindividual membrane modules. Typically, membrane separationinstallations are constructed using a number of membrane separationmodules which are stacked vertically to form a skid and create therequired membrane area to process a fluid. This design requires amultitude of external connections to feed each individual membranemodule and remove the processed fluid. As a result, packing of suchlarge systems may present a problem because of the need to accommodatethe input, output and permeate ports of each module.

Such individual skids are constructed using structural steel to supporteach set of membrane modules. Such structural steel supports, however,add weight to the overall membrane system and increase the area requiredto install each individual skid. Consequently, such larger systems areheavier and more expensive to manufacture due to the quantity ofmaterials needed to produce the structural steel supports, as well as,individual tubes for each module. Such larger systems are also morecomplex due to the increased number of connections between the membranemodules and common headers used to deliver and remove fluids from theskid.

Thus, there is a need and a demand for separation systems whichincorporate an increased number of membrane cartridges or modules in agiven area. In particular, there is a need and a demand for separationsystems which incorporate multiple membrane cartridges into a singlepressure vessel.

There is also a need and a demand for separation systems havingsimplified process fluid stream connections. Further, for example, thereis a need and a demand for separation systems that permit feed streamdelivery to, residual stream removal from, and permeate stream removalfrom a multitude of membrane cartridges at a reduced number oflocations.

There is a further need and a demand for separation systems that areless expensive to produce.

SUMMARY

We therefore provide a permeate adapter for use within a pressurevessel. The permeate adapter includes a front portion with a permeateopening for receiving an end of a permeate passage tube of a membranecartridge and for being in fluid communication with a permeatereservoir. The front portion additionally includes one or more fluidopenings. A back portion is disposed opposite the front portion and alsoincludes one or more fluid openings. Fluid passageways are connectedbetween the front portion fluid openings and the back portion fluidopenings. At the front portion of the permeate adapter, the fluidpassageways receive an end of a membrane cartridge. At the back portion,the fluid passageways are in fluid communication with a fluid reservoiradjacent the back portion of the permeate adapter.

A separation system includes an elongated pressure vessel with a feedstream inlet, a residual stream outlet, and at least one permeate streamoutlet. A first tube sheet assembly is disposed within the pressurevessel and defines a first permeate reservoir. The first tube sheetassembly includes a first pair of tube sheets and one or more firstsleeves disposed therebetween. The first permeate reservoir is in fluidcommunication with the at least one permeate stream outlet. Theseparation system further includes a first fluid reservoir disposedwithin the pressure vessel between a first end of the pressure vesseland the first tube sheet assembly. A plurality of membrane cartridgeassemblies is disposed within the pressure vessel and extends betweenthe first end and a second end of the pressure vessel. At least onemembrane cartridge assembly includes a first permeate adapter and amembrane cartridge, where the first permeate adapter is joined to afirst end of the membrane cartridge and disposed within one of the firstsleeves. The first permeate adapter includes a front portion having atleast one fluid opening and a permeate opening that receives an end of apermeate passage tube of a membrane cartridge at the front portion andthat is in fluid communication with a permeate reservoir. The firstpermeate adapter further includes a back portion with at least one fluidopening, and at least one fluid passageway connected between the frontportion fluid opening and the back portion fluid opening. The fluidpassageway receives an end of a membrane cartridge at the front portionand is in fluid communication with a fluid reservoir adjacent the backportion.

A pressure vessel is provided that comprises an elongated housingcontaining a first fluid reservoir adjacent a first end of the housing,a second fluid reservoir adjacent a second end of the housing, a firstpermeate reservoir adjacent the first fluid reservoir defined by a firsttube sheet assembly, a second permeate reservoir adjacent the secondfluid reservoir defined by a second tube sheet assembly, and a cartridgechamber disposed between the first and second permeate reservoirs, thefirst tube sheet assembly including a first tube sheet, a second tubesheet and a plurality of first sleeves disposed therebetween, the secondtube sheet assembly including a third tube sheet, a fourth tube sheetand a plurality of second sleeves disposed therebetween, the pluralityof second sleeves corresponding to the plurality of first sleeves. Thepressure vessel further includes a feed stream inlet, a residual streamoutlet, at least one first permeate stream outlet in fluid communicationwith the first permeate reservoir, and at least one second permeatestream outlet in fluid communication with the second permeate reservoir.A plurality of membrane cartridge assemblies is disposed within theelongated housing and extends between the first fluid reservoir and thesecond fluid reservoir. Each membrane cartridge assembly includes afirst permeate adapter, a membrane cartridge, and a second permeateadapter. The first permeate adapter is joined to a first end of themembrane cartridge and disposed within one of the first sleeves, thefirst permeate adapter is in fluid communication with the first fluidreservoir, the first end of the membrane cartridge and the firstpermeate reservoir. The membrane cartridge is disposed within a membranepressure tube. The second permeate adapter is joined to a second end ofthe membrane cartridge and disposed within the corresponding secondsleeve. The second permeate adapter is in fluid communication with thesecond fluid reservoir, the second end of the membrane cartridge and thesecond permeate reservoir. The first permeate adapter and the secondpermeate adapter each comprise a front portion having at least one fluidopening and a permeate opening that receives an end of a permeatepassage tube of a membrane cartridge at the front portion and that is influid communication with the first and/or second permeate reservoir. Theadapters further include a back portion having at least one fluidopening and at least one fluid passageway connected between the frontportion fluid opening and the back portion fluid opening. The fluidpassageway receives an end of a membrane cartridge at the front portionand is in fluid communication with the first and/or second fluidreservoir adjacent the back portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a separation system in accordance withone embodiment.

FIG. 2 is a cross-sectional side view of the separation system shown inFIG. 1.

FIG. 3 is a detail view of section 3 shown in FIG. 2.

FIG. 4 is a cross-sectional end view of the separation system shown inFIG. 1.

FIG. 5 is a perspective view of a sleeve for use in the tube sheetassembly shown in FIG. 3.

FIG. 6 is a cross-sectional view of a membrane cartridge assembly foruse in the separation system shown in FIG. 1.

FIG. 7 is a front perspective view of a permeate adapter.

FIG. 8 is a cross-sectional view of the permeate adapter shown in FIG.7.

FIG. 9 is a side view of the permeate adapter shown in FIG. 7.

FIG. 10 is a cross-sectional side view of a separation system inaccordance with another embodiment.

FIG. 11 is an end view of a separation system in accordance with afurther embodiment.

FIG. 12 is an end view of a separation system in accordance with yetanother embodiment.

DETAILED DESCRIPTION

We provide a separation system for use in separation of a fluid feed viaa plurality of membrane cartridges or modules disposed within a pressurevessel. As described in greater detail below, the separation systemshave improved packing and reduced space requirements. Moreover, weprovide separation systems that are lighter and less expensive tomanufacture. Further, separation systems having simplified and/or areduced number of process stream connections are provided.

The representative structures may be practiced or embodied by, in orwith separation systems having a variety of different specificstructures. As representative, FIG. 1 illustrates a separation system,generally designated by the reference numeral 10, in accordance with onerepresentative structure. While separation systems have various uses,the structures are believed to have particular utility for use in orwith the separation of one or more gases from a mixture of gases. It isto be understood, however, that the broader practice of the embodimentsare not necessarily limited to use for the separation of gases from amixture of gases. Other fluid separations such as, for example, liquidseparations by reverse osmosis processing can, if desired, also bepracticed employing separation systems in accordance with theembodiments.

Returning to FIG. 1, the separation system 10 includes a pressure vessel12. The pressure vessel 12 is suitably in the form of an elongatedhousing having a generally cylindrical or tubular cylindrical centersection 14. The center section 14 of the pressure vessel 12 maygenerally be constructed to have any size suitable to house a desiredplurality of membrane cartridge assemblies. The inner diameter ofpressure vessels may be adjusted to accommodate various operation andprocess conditions to achieve a desired flow per membrane cartridgeassembly and to meet the required product specification.

The center section 14 of the pressure vessel 12 may have an innerdiameter of about 0.6 m (2 ft.) to about 6.1 m (20 ft.). In accordancewith another embodiment the center section 14 of the pressure vessel 12may have an inner diameter of about 1.8 m (6 ft.) to about 6.1 m (20ft.). The center section 14 of the pressure vessel 12 may have an innerdiameter of about 1.8 m (6 ft.) to about 4.3 (14 ft.).

Each of a first end 16 and/or a second end 18 of the pressure vessel 12may be terminated with a hemispherical or semi-hemispherical head 20 and21, respectively. The head 20 and/or the head 21 may include a manway,22 and 23 (shown in FIG. 2), respectively, to provide access to theinterior of the pressure vessel 12. Alternatively, one of the first orsecond ends, 16 and 18, respectively, may be closed to the atmospheresuch as by way of a blind flange (not shown) which forms a solid endcover at one of the first or second ends, 16 and 18, respectively, ofthe pressure vessel 12.

The pressure vessels may be constructed from various suitable materials,such as various metals or metal alloys, desirably at least relativelyinert to the fluid stream materials passing therethrough. For example,stainless steel in the form of a plate having a thickness of about 5 cmto about 15.25 cm (about 2 to about 6 inches) may be rolled or otherwiseused to form the pressure vessel 12 in accordance with one embodiment.Alternatively, pressure vessels can be constructed of other metallicmaterials such as, for example, aluminum, carbon steel and/or stainlesssteel. In accordance with certain embodiments, the pressure vessel 12can withstand pressures up to about 15.2 MPa (about 2200 psi).

The pressure vessel 12 includes a feed stream inlet or port 24 adjacentor near the pressure vessel first end 16 and a residual stream outlet orport 26 adjacent the pressure vessel second end 18. FIG. 1 depicts boththe feed stream inlet 24 and the residual stream outlet 26 orientedvertically. However, the feed stream inlet 24 and/or the residual streamoutlet 26 may be appropriately disposed anywhere about the circumferenceof the pressure vessel 12 adjacent the respective desired pressurevessel first end 16 and/or the pressure vessel second end 18.

Both the feed stream inlet 24 and the residual stream outlet 26 may beadjacent the pressure vessel first end 16 or the second pressure vesselend 18. In a further embodiment, the pressure vessel 12 may includemultiple feed stream inlets and/or residual stream outlets located aboutthe circumference of the pressure vessel adjacent the pressure vesselfirst end 16 and/or the pressure vessel second end 18.

The pressure vessel 12 further includes at least one first permeatestream outlet or port 28 adjacent or near the pressure vessel first end16. For example, referring to FIG. 1, the pressure vessel 12 includesfour first permeate stream outlets, 25, 27, 28 and 29, respectively.Additionally or alternatively, the pressure vessel 12 may include atleast one second permeate stream outlet or port 30 adjacent or near thepressure vessel second end 18. For example, the pressure vessel 12illustrated in FIG. 1 also includes four second permeate stream outlets,three of which are visible, 30, 31 and 33, respectively. The secondpermeate stream outlets are arranged in a manner similar to the firstpermeate stream outlets, 25, 27, 28 and 29, respectively. The number offirst and/or second permeate stream outlets, 28 and 30, respectively,may vary depending upon the particular application and/or processspecification.

The first and/or second permeate stream outlets, 28 and 30,respectively, can desirably be disposed at appropriate select locationsabout the circumference of the pressure vessel 12 and radially extendingtherefrom, such as shown in FIG. 1. In particular, FIG. 1 shows thefirst permeate stream outlets 28 and the second permeate stream outlets30 as extending from the pressure vessel 12 perpendicular to the feedstream inlet 24 and the residual stream outlet 26.

Turning to FIG. 2, the separation system 10 further includes a firsttube sheet assembly 32 disposed within the pressure vessel 12 adjacentthe pressure vessel first end 16. The first tube sheet assembly definesa first fluid reservoir 34 disposed between the pressure vessel firstend 16 and the first tube sheet assembly 32 and a first permeatereservoir 36. The first fluid reservoir 34 is in fluid communicationwith the feed stream inlet port 24 and the first permeate reservoir 36is in fluid communication with at least one permeate stream outlet 28.

The first fluid reservoir 34 may be a feed reservoir and the secondfluid reservoir 46 may be a residual reservoir. Alternatively, the firstfluid reservoir 34 may be a residual reservoir and the second fluidreservoir 46 may be a feed reservoir.

As shown in detail in FIG. 3, the first tube sheet assembly 32 includesa first pair of tube sheets 38, which includes a first tube sheet 40 anda second tube sheet 42, which define the first permeate reservoir 36therebetween. The first tube sheet assembly 32 further includes aplurality of first sleeves 50 disposed between the first tube sheet 40and the second tube sheet 42. The first tube sheet 40 has a plurality offirst openings 54 formed therethrough and the second tube sheet 42 has aplurality of corresponding second openings 58 formed therethrough.

Each first sleeve 50 has a first end 52 disposed within and extendingthrough one of the first openings 54 in the first tube sheet 40 and asecond end 56 disposed within and extending through the correspondingsecond opening 58 in the second tube sheet 42 forming a plurality offirst channels 60 which extend through the first tube sheet assembly 32.

The first openings 54 and the corresponding second openings 58 may bearranged in any suitable pattern, array or arrangement. For example, asillustrated in FIG. 4, the first openings 54 in tube sheet 40 may beformed in a honeycomb-like pattern. Accordingly, the second tube sheet42 would have a corresponding honeycomb-like pattern of the secondopenings 58 (not shown). The first and second openings 54 and 58,respectively, can be laid out such that the first sleeves 50 arearranged in a manner similar to that of a heat exchanger.

The first and second tube sheets, 40 and 42, respectively, are held inplace and at a proper or desired distance from each other by the firstsleeves 50, as illustrated in FIG. 3. For example, the first sleeves 50may be configured to maintain a distance between the first tube sheet 40and the second tube sheet 42 of about 10.2 cm (about 4 inches) to about91.4 cm (about 36 inches.). Also, the first sleeves 50 may be configuredto maintain a distance between the first tube sheet 40 and the secondtube sheet 42 of about 15.2 cm (about 6 inches) to about 45.7 cm (about18 inches). Further, the first sleeves 50 may be configured to maintaina distance between the first tube sheet 40 and the second tube sheet 42of about 17.8 cm (about 7 inches).

Suitably, as shown in FIG. 3, the first sleeves 50 are welded orotherwise permanently joined to the first tube sheet 40 and the secondtube sheet 42 such as by a structural and sealing joint 61. The firstsleeves 50 generally create a structural support system that reacts toloads on the first and second tube sheets, 40 and 42, respectively,created by differential pressures within the pressure vessel 12.

The first and second tube sheets, 40 and 42, respectively, can beconstructed or fabricated from a metallic material such as, for example,aluminum, carbon steel, stainless steel or a combination thereof.Similarly, the first sleeves 50 can be constructed or fabricated from ametallic material such as, for example, aluminum, carbon steel,stainless steel or a combination thereof.

The first tube sheet assembly 32 may further include structural supportmembers (not shown) extending between the first tube sheet 40 and thesecond tube sheet 42 and disposed between, around or next to adjacentsleeves 50 to provide additional structural stability to the first tubesheet assembly 32. Such structural support members may be constructed,for example, from schedule 80 carbon steel pipe having a diameter ofabout 5 cm (about 2 inches).

The pressure vessel 12 may also include a second tube sheet assembly 44disposed within the pressure vessel 12 adjacent the pressure vesselsecond end 18. The second tube sheet assembly 44 defines a second fluidreservoir 46 disposed between the second tube sheet assembly 44 and thepressure vessel second end 18 and a second permeate reservoir 48. Thesecond fluid reservoir 46 is in fluid communication with residual streamoutlet 26 and the second permeate reservoir 48 is in fluid communicationwith at least one second permeate stream outlet 30.

The second tube sheet assembly 44 may be constructed in a manner similarto the first tube sheet assembly 32, as shown in FIGS. 2 and 3. Inparticular, as illustrated in FIG. 2, the second tube sheet assembly 44may include a second pair of tube sheets, which includes a third tubesheet 62 and a fourth tube sheet 64, which define the second permeatereservoir 48 therebetween. The second tube sheet assembly 44 furtherincludes a plurality of second sleeves 66 disposed between the thirdtube sheet 62 and the fourth tube sheet 64. The third tube sheet 62 hasa plurality of third openings formed therethrough and the fourth tubesheet 64 has a plurality of corresponding fourth openings formedtherethrough.

Each second sleeve 66 has a first end disposed within and extendingthrough one of the third openings in the third tube sheet 62 and asecond end disposed within and extending through the correspondingfourth opening in the fourth tube sheet 64 forming a plurality of secondchannels 68 which extend through the second tube sheet assembly 44. Asshown in FIG. 2, the plurality of first channels 60 generally correspondto the plurality of second channels 68.

FIG. 5 illustrates, in greater detail, a sleeve 110, whichadvantageously permits or otherwise allows permeate material to becarried into an associated permeate reservoir. The sleeve 110 includes afirst end 112, a second end 114 and a body portion 116 extending betweenthe first end 112 and the second end 114. The body portion 116 issuitably in the form of a tube or otherwise hollow structure such asforms one of the first channels 60 which extends through the first tubesheet assembly 32 or one of the second channels 68 which extends throughthe second tube sheet assembly 44, as shown in FIG. 2.

The body portion 116 of the sleeve 110 includes at least one permeateexit opening 118 formed therethrough to permit permeate material to becarried into an associated permeate reservoir. For example, asillustrated in FIG. 5, the sleeve 110 may include three permeate exitopenings 118 formed through the body portion 116. The sleeve 110 mayinclude two, three, four or more permeate exit openings 118 toaccommodate desired process specifications.

The body portion 116 of the sleeve 110 further includes a first sealingarea 113 disposed between the first end 112 and the at least onepermeate exit opening 118 and/or a second sealing area 115 disposedbetween the second end 114 and the at least one permeate exit opening118 to restrain or maintain an associated permeate adapter within thesleeve.

The first sealing area 113 can include a retaining clip groove 120formed or cut into an inner surface 111 of the sleeve which restrains ormaintains an associated permeate adapter within the sleeve. The secondsealing area 115 can also include a retaining clip groove 121 formed orcut into the inner surface 111 of the adapter sleeve which restrains ormaintains an associated permeate adapter within the sleeve 110.

Alternatively or additionally, the body portion 116 of the sleeve 110can include at least one hole, aperture or opening (not shown) formed orcut through the body portion 116 of the sleeve 110 generally associatedwith the first and/or second sealing areas, 113 and 115, respectively,for receiving a pin which restrains or maintains an associated permeateadapter within the sleeve 110.

Returning to FIG. 2, the separation system 10 further includes aplurality of membrane cartridge assemblies 70 disposed within thepressure vessel 12 and extending between the pressure vessel first end16 and the pressure vessel second end 18. In accordance with certainembodiments, at least a portion of the membrane cartridge assemblies 70are disposed within a cartridge chamber 72 disposed between the firsttube sheet assembly 32 and the second tube sheet assembly 44.

The separation system 10, as shown in FIG. 2, is generally known orreferred to as a single-pass system. In practice, a fluid is fed to thefirst fluid reservoir 34 via the feed stream inlet 24. The fluid passesinto the membrane cartridge assemblies 70, wherein select components ofthe fluid permeate through membrane separation elements contained withinthe membrane cartridge assemblies 70 and are collected in the firstpermeate reservoir 36 and/or the second permeate reservoir 48 and areremoved from the separation system via the at least one first permeatestream outlet 28 and/or the at least one second permeate stream outlet30. Non-permeate or residual components of the fluid exit the membranecartridge assemblies 70 and are collected in the second fluid reservoir46. The non-permeate or residual fluid is removed from the separationsystem via the residual stream outlet 26.

FIG. 6 illustrates, in greater detail, a membrane cartridge assembly210. The membrane cartridge assembly 210 includes a membrane cartridge212 which may contain one or more membrane separation elements 222. Themembrane cartridge 212 illustrated in FIG. 6, for example, includes fivemembrane separation elements 222 which are joined sequentially or inseries. The number of membrane separation elements 222 employed inparticular membrane cartridge assemblies 210 is generally applicationdependent.

Individual membrane separation elements 222 may be interconnected by aclamp or other selected connection or coupling, such as designated byreference numeral 224. One suitable connection or coupling 224 forinterconnecting individual membrane separation elements 222 isdisclosed, for example, in commonly assigned U.S. Pat. No. 5,851,267.

Each membrane separation element 222 includes a central permeate tube226 which, when the membrane separation elements 222 are interconnected,form, at least in part, a generally centrally disposed permeate passagetube 228 which extends through the membrane cartridge 212 from a firstend 216 to a second end 220. The central permeate tubes 226 include aplurality of perforations 230 for receiving fluid which permeatesthrough the membrane separation elements 222.

The membrane cartridge 212 may advantageously include a membranepressure tube 232 which provides support for the membrane cartridgeassemblies 210 and prevents the membrane cartridges 212 from sagging.Additionally, the membrane pressure tube 232 generally seals a feed sideof the membrane separation elements 222 from a residual side of themembrane separation element 222.

The membrane pressure tube 232 may be in the form of a cylindrical tubewhich houses or contains the membrane separation elements 222. Themembrane pressure tube 232 may be constructed from various metallicmaterials, such as, for example, aluminum, carbon steel, and/orstainless steel, or non-metallic materials such as, for example, carbonfiber reinforced polymer materials. The membrane pressure tube 232 maybe constructed from light-weight materials and may withstand pressuresof about 3.5 to about 7.0 kg/cm² (about 50 to about 100 psi).

The membrane cartridge assembly 210 includes a first permeate adapter214 joined to the first end 216 of the membrane cartridge 212. The firstpermeate adapter may be further joined to a first end 234 of thepermeate passage tube 228.

The membrane cartridge assembly 210 may further include a secondpermeate adapter 218 joined to a second end 220 of the membranecartridge 212. The second permeate adapter 218 may be further joined toa second end 238 of the permeate passage tube 228.

The cartridge chamber 72, such as shown in FIG. 2, may include aplurality of racks or intermediate supports 73 to provide support forthe membrane cartridge assemblies 70. Such racks prevent the portion ofthe membrane cartridge assemblies 70 disposed within the cartridgechamber 72, from sagging which alleviates or eliminates stress on thecouplings between the membrane cartridge 70 and associated first and/orsecond permeate adapters.

As illustrated in FIG. 6, the membrane pressure tube 232 prevents theportion of the membrane cartridge assembly 210 within the cartridgechamber from sagging which alleviates or eliminates stress on thecouplings between the membrane cartridge 212 and the first and/or secondpermeate adapters, 214 and 218, respectively. Racks or intermediatesupports can be optionally removed.

The racks 73 may be positioned at intervals within the cartridge chamber72 and may extend horizontally across a width of the cartridge chamber72. For example, the racks may be constructed from tubing having squareor round cross section or from angle bars that are disposed across thewidth of the cartridge chamber at about 1.2 to about 1.8 meter (about 4to about 6 foot) intervals.

Alternatively, the racks may extend down a length of the cartridgechamber 72 (not shown). For example, the racks may be constructed fromhalf tubes having a semi-circular or triangular cross-section thatextend from a first end to a second end of the cartridge chamber, e.g.,from the first tube sheet assembly 32 to the second tube sheet assembly44, as shown in FIG. 2.

FIG. 7 illustrates a permeate adapter 710, such as the first and/orsecond permeate adapters 214 and 218 of FIG. 6. The permeate adapter 710permits or otherwise allows permeate material to be carried out of amembrane cartridge, such as the membrane cartridge 212 as shown in FIG.6, into an associated permeate reservoir, such as the permeate reservoir36 as shown in FIG. 2.

With reference to FIG. 8, a front view of the permeate adapter 710 isshown. The permeate adapter 710 includes a front portion 712. The frontportion 712 includes at least one fluid opening 713 and at least onepermeate opening 714. The permeate opening 714 receives an end of apermeate passage tube, such as the first end 234 or the second end 238of the permeate passage tube 228 as shown in FIG. 6. Further, thepermeate opening 714 is in fluid communication with a permeatereservoir, such as the permeate reservoir 36 as shown in FIG. 2.

With reference again to FIG. 7, the permeate adapter 710 also includes aback portion 722, oppositely disposed from the front portion 712. Theback portion 722 has at least one fluid opening 723.

At least one fluid passageway 732 is connected between the front portionfluid openings 713 and the back portions fluid openings 723. At thefront portion 712, the at least one fluid passageway 732 receives an endof a membrane cartridge, such as the first end 216 or the second end 220of the membrane cartridge 212 as shown in FIG. 6. Adjacent the backportion 722, the at least one fluid passageway 732 is in fluidcommunication with a fluid reservoir, such as the first fluid reservoir34 or the second fluid reservoir 46 as shown in FIG. 2. The permeateadapter 710 may include one or more than one fluid passageways 732depending upon the size of the permeate adapter 710 and/or the processin which the permeate adapter 710 is employed.

The front portion 712 and the back portion 722 of the permeate adapter710 may be steel end-plates with the front portion being a front plateand the back portion being a back plate. The front and back portions 712and 714 may alternately be formed of composite, man-made, or ceramicmaterials. The one or more fluid passageways 732 may be a steel,composite, man-made, or ceramic tube or pipe. The one or more fluidpassageways 732 may be welded or otherwise joined to the front portion712 and the back portion 722 with the one or more fluid passageways 732,the front portion 712 and the back portion 722 being discrete structuralbodies.

The front portion 712 of the permeate adapter 710 includes a front notch728 formed along the outer edge of the front portion 712. The frontnotch 728 contains a front o-ring inserted in the front notch 728 forproviding isolation between the permeate adapter 710 and a membranecartridge chamber, such as the cartridge chamber 72 of FIG. 2. The backportion 722 includes a back notch 730 formed along the outer edge of theback portion 722. A back o-ring is inserted in the back notch 730 toprovide isolation between the permeate adapter 710 and a fluidreservoir, such as the fluid reservoir 34 or 46 of FIG. 2.

The permeate adapter 710 may be disposed within an associated sleeve,such as the sleeve 110 illustrated in FIG. 5. Once disposed within anassociated sleeve, the front o-ring disposed in the front notch 728forms a seal between the permeate adapter 710 and the associated sleevewhereby the space between the front portion 712 and back portion 722 isisolated from an associated cartridge chamber, such as the cartridgechamber 72 of FIG. 2. Additionally, the back o-ring disposed in the backnotch 730 forms a seal between the permeate adapter 710 and theassociated sleeve whereby the space between the front portion 712 andback portion 722 is isolated from an associated fluid reservoir, such asthe fluid reservoir 34 as shown in FIG. 2.

FIG. 9 is a side view of the permeate adapter 710. The front notch 728formed in the front portion 712 and the back notch 730 formed in theback portion 722 may be seen in the side view. Also illustrated are fourfluid passageways 732 and the permeate opening 714.

As the permeate opening 714 receives an end of a permeate passage tube,the fluid received from the permeate passage tube flows around the fluidpassageways 732 in the space between the front portion 712 and the backportion 722 of the permeate adapter 710. Thus, once the permeate adapter710 is disposed within an associate sleeve, the fluid, such as permeatematerial, exits through the permeate exit openings 118 of the associatedsleeve 110 of FIG. 5.

In practice, the permeate adapter 710, once joined to a respective endof an associated permeate passage tube, places an associated membranecartridge, such as membrane cartridge 212 of FIG. 6, in fluidcommunication with an associated permeate reservoir via the permeateopening 714 and the open space between the front portion 712 and theback portion 722. Further, the back portion 722 of the permeate adapter710 is placed in fluid communication with an associated fluid reservoir,such as the fluid reservoir 34 of FIG. 2, through the back portion fluidopenings 723. The front portion 712 of the permeate adapter 710 isplaced in fluid communication with an end of the associated membranecartridge, such as the first end 216 or the second end 220 of themembrane cartridge 212 of FIG. 6, through the front fluid openings 713.

In practice, referring to FIG. 6, a fluid to be separated is fed to aback portion 242 of the first permeate adapter 214. The fluid passesthrough first fluid passageways 244 into the first end 216 of membranecartridge 212. Select components of the fluid permeate through themembrane separation elements 222 and are collected in the permeatepassage tube 228. The permeated components are carried into the firstand/or second permeate adapters, 214 and 218, via the permeate passagetube 228 where they are discharged from the first and/or second permeateadapters into an associate permeate reservoir via the space between thefront portion 712 and the back portion 722 of the permeate adapter 710,such as shown in FIG. 7. Non-permeate or residual components in thefluid are carried out of the second end 220 of the membrane cartridge212 into the second permeate adapter 218 where they exit a back portion246 of the second permeate adapter 218 via second fluid passageways 248.

The permeate adapter 710 weighs less, costs less, and has fabricationbenefits over permeate adapters formed from a solid piece of material,such as metal. The permeate adapter 710 is comprised of a front portion712, a back portion 722, and one or more fluid passageways 732. The oneor more fluid passageways 732 are welded or otherwise joined to thefront and back portions 712 and 722.

In contrast, a permeate adapter formed from a solid piece of materialmay include a central blind bore formed within the permeate adapter, oneor more permeate discharge ports, as well as one or more fluid ports.This solid piece of material with the bore and ports may weigh, forexample, approximately 50% more than the permeate adapter 710.Additionally, the solid piece of material used to form a permeateadapter may cost more than the front portion 712, the back portion 722,and the one or more fluid passageways 732 used to form the permeateadapter 710. Furthermore, extra cost may be incurred in the fabricationof the permeate adapter from a solid piece of material as thefabrication process takes more time and is more complicated than thefabrication process of the permeate adapter 710.

In an alternative embodiment, as shown in FIG. 10, a separation system410 includes a pressure vessel 412 containing a first fluid reservoir414 adjacent a first end 416 of the pressure vessel 412, a second fluidreservoir 418 adjacent a second end 420 of the pressure vessel 412, afirst tube sheet assembly 422 adjacent the first fluid reservoir 414, asecond tube sheet assembly 424 adjacent the second fluid reservoir 418,and a cartridge chamber 426 disposed between the first tube sheetassembly 422 and the second tube sheet assembly 424.

The first fluid reservoir 414 contains a divider plate 428 extendingfrom the first end 416 of the pressure vessel 412 to the first tubesheet assembly 422. The divider plate 428 defines a feed chamber 430 influid communication with a feed stream inlet 432 and a residual chamber434 in fluid communication with a residual stream outlet 436. The secondfluid reservoir 418 may be in fluid communication with at least onefluid stream port 446.

The first and second tube sheet assemblies, 422 and 424, respectively,define a first permeate reservoir 438 and a second permeate reservoir440, respectively. The first permeate reservoir 438 is in fluidcommunication with at least one first permeate stream outlet (not shown)and the second permeate reservoir 440 is in fluid communication with atleast one second permeate stream outlet (not shown).

The cartridge chamber 426 includes at least one first membrane cartridgeassembly 442 and at least one second membrane cartridge assembly 444.The at least one first membrane cartridge assembly 442 and the at leastone second membrane cartridge assembly 444 may be constructed such asdescribed herein and shown in FIG. 6. The at least one first membranecartridge assembly 442 extends from the first tube sheet assembly 422 tothe second tube sheet assembly 424 and is in fluid communication withthe feed chamber 430, the first permeate reservoir 438, the secondpermeate reservoir 440, and the second fluid reservoir 418. The at leastone second membrane cartridge assembly 444 extends from the first tubesheet assembly 422 to the second tube sheet assembly 424 and is in fluidcommunication with the residual chamber 434, the first permeatereservoir 438, the second permeate reservoir 440 and the second fluidreservoir 418.

In practice, a fluid is fed into the feed chamber 430 via feed streaminlet 432 and passes into the at least one first membrane cartridgeassembly 442. Select components of the fluid permeate through membraneelements disposed within the at least one first membrane cartridgeassembly 442 and are collected in the first permeate reservoir 438and/or the second permeate reservoir 440. Non-permeate or residualcomponents of the fluid exit the at least one first membrane cartridgeassembly 442 and are collected in the second fluid reservoir 418, alsoknown as a recycle reservoir. The non-permeate or residual fluid passesfrom the second fluid reservoir 418 into the at least one secondmembrane assembly 444. Select components of the residual fluid permeatethrough membrane elements disposed within the at least one secondmembrane cartridge assembly 444 and are collected in the first permeatereservoir 438 and/or the second permeate reservoir 440. The remainingfluid containing non-permeate components exits the at least one secondmembrane cartridge assembly 444 into the residual chamber 434 where itis removed from the pressure vessel 412 via residual stream outlet 436.A separation system 410 operated in this manner is generally known orreferred to as a double-pass system.

The divider plate 428 may be mounted within the first fluid chamber 414using a hinge or similar moveable attachment such that the divider plate428 may be moved to allow access to the interior of the pressure vessel412 such a via a manway 446 formed in the first end 416 of the pressurevessel 412. In accordance with another embodiment, the divider plate 428may be releasably mounted within the first fluid reservoir 414 wherebythe divider plate 428 may be removed from the first fluid reservoir 414to allow access to the first tube sheet assembly 422 and/or to convertthe separation system 410 from a double-pass system to a single-passsystem as described herein above.

The separation system 410 can further include a divider plate such as,for example, similar to divider plate 428, disposed within the secondfluid reservoir 418 extending from the second end 420 of the pressurevessel to the second tube sheet assembly 424. The divider plate 428within the first fluid reservoir 414 can define first and second feedchambers (e.g., chambers 430 and 434, respectively) and the dividerplate within the second fluid reservoir 418 can define opposing firstand second residual reservoirs. The at least one first membranecartridge assembly 442 extends from the first tube sheet assembly 422 tothe second tube sheet assembly 424 and is in fluid communication withthe first feed chamber (e.g., chamber 430), the first permeate reservoir438, the second permeate reservoir 440, and the opposing first residualchamber. The at least one second membrane cartridge assembly 444 extendsfrom the first tube sheet assembly 422 to the second tube sheet assembly424 and is in fluid communication with the second feed chamber (e.g.,chamber 434), the first permeate reservoir 438, the second permeatereservoir 440, and the opposing second residual chamber. The firstresidual chamber is in fluid communication with a first fluid streamport 448 and the second residual is in fluid communication with a secondfluid port (e.g., fluid stream port 446). A separation system 410operated in this manner is generally allows for or provides a 50%turndown (i.e., a 50% reduction in the volume of gas treated within thesystem) when fluid is fed to one of the first and second feed chambers(e.g., chambers 430 and 434).

The divider plate 428 can extend through the first tube sheet assembly422 and define first and second permeate reservoirs therein.Additionally, or alternatively, a divider plate, similar to the dividerplate 428, disposed within the second fluid reservoir 418 can extendthrough the second tube sheet assembly 424 and define first and secondpermeate reservoirs therein.

Two or more divider plates, such as, for example, similar to the dividerplate 428, can be disposed within the first fluid reservoirs 414 todefine three or more fluid chambers in the first end 416 of the pressurevessel 412. Additionally or alternatively, two or more divider plates,such as, for example, similar to the divider plate 428, can be disposedwithin the second fluid reservoirs 418 to define three or more fluidchambers in the second end 420 of the pressure vessel 412.

Optionally, separation systems such as shown in FIG. 2 or 10 may furtherinclude at least one condensation port (not shown) in fluidcommunication with an associated cartridge chamber, such as thecartridge chamber 72 shown in FIG. 2 or the cartridge chamber 426 showin FIG. 10.

As shown in FIG. 11, a separation system 510 includes an elongatedpressure vessel 512 including a feed stream inlet (not shown), aresidual stream outlet (not shown) and plurality of permeate streamoutlets 514. The separation system 510 further includes a plurality ofmembrane cartridge assemblies 516 extending from a first end to a secondend of the pressure vessel 512. The membrane cartridge assemblies 516,constructed such as, for example, shown in FIG. 6, include at least afirst permeate adapter 518, constructed such as described herein andshown in FIGS. 7-9, joined to a membrane cartridge (not shown).

The separation system 510 additionally includes a plurality of permeateheaders 520 extending through the pressure vessel 512 perpendicular tothe plurality of membrane cartridge assemblies 516. Each permeate header520 is in fluid communication with a first permeate stream outlet 522, asecond permeate stream outlet 524, and at least one membrane cartridgeassembly 516. Each of the plurality of permeate headers 520 may includea plurality of adapter notches 526 for receiving one or morecorresponding membrane cartridge assemblies 516. In practice, a membraneadapter notch 526 receives a permeate adapter 518 joined to acorresponding membrane cartridge assembly 516.

The separation system 510 can further include a permeate reservoir (notshown) having at least one permeate stream outlet for collectingpermeate from the plurality of permeate headers 520. Such permeatereservoir can be in the form of a ring which surrounds or encircles theseparation system 510 such that the first and second permeate outlets,522 and 524, respectively, of each permeate header 520 are in fluidcommunication with the permeate reservoir. In practice, individualpermeate streams from the plurality of permeate headers 520 are combinedwithin the permeate reservoir and such combined permeate stream can bedrawn from the separation system 510 using a reduced number of permeatestream outlets.

As shown in FIG. 12, a separation system 610 includes an elongatedpressure vessel 612 including a feed stream inlet (not shown), aresidual stream outlet (not shown) and plurality of permeate streamoutlets 614. The separation system further includes a plurality ofmembrane cartridge assemblies 616 extending from a first end to a secondend of the pressure vessel 612. The membrane cartridge assemblies 616include at least a first permeate adapter 618, constructed such asdescribed herein and shown in FIGS. 7-9, attached to a membranecartridge (not shown).

The separation system 610 includes a plurality of permeate headers 620extending through the pressure vessel 612 perpendicular to the pluralityof membrane cartridge assemblies 616. Each permeate header 620 includesan internal header portion 622 disposed within the pressure vessel 612.The internal header portion 622 of each permeate header 620 isreleasably attached to a first permeate stream outlet 624 and/or asecond permeate stream outlet 626. A first end 628 of at least onemembrane cartridge assembly 616 is releasably attached to an internalheader portion 622 of an associated permeate header 620.

Each permeate header 620 further includes a first pair of raised faceflanges 630 and/or a second pair of raised face flanges 632. The firstpair of raised face flanges 630 releasably attach the internal headerportion 622 of one of the permeate headers 620 to an associated firstpermeate stream outlet 624 and the second pair of raised face flanges632 releasably attach the internal header portion 622 to a correspondingsecond permeate stream outlet 626.

The separation system 610 can further include a permeate reservoirsimilar to the permeate reservoir described above in conjunction withseparation system 510.

As described above, a separation system which incorporates a pluralityof membrane cartridge assemblies within a pressure vessel that allowspermeate to be transmitted from the plurality of membrane cartridgesinto one or more common permeate reservoirs within the pressure vesselwhere the permeate may be removed from the separation system via atleast one permeate stream exit port is provided. Thus, feed streamdelivery, residual stream removal from, and permeate stream removal forma multitude of membrane cartridges at a reduced number of locations isprovided.

As detailed herein, improvements and benefits realizable through thepractice include, a separation system that produces or results inimproved packaging at the skid level, reduced cost and installationweight due to the elimination of piping or flow connections toindividual membrane cartridges or modules, and increased flexibilityregarding flow configurations without requiring significant hardwaresubstitutions.

The structures illustratively disclosed herein suitably may be practicedin the absence of any element, step, part, component, or ingredientwhich is not specifically disclosed herein.

While in the foregoing detailed description of this disclosure has beendescribed in relation to certain representative structures thereof, andmany details have been set forth for purposes of illustration, it willbe apparent to those skilled in the art that the disclosure can bevaried considerably without departing from the basic principles of thedisclosure.

1. A permeate adapter for use within a pressure vessel, the permeateadapter comprising: a front plate having at least one fluid opening anda permeate opening which receives an end of a permeate passage tube of amembrane cartridge at the front plate and is in fluid communication witha permeate reservoir; a back plate longitudinally spaced from the frontplate and having at least one fluid opening; at least one tube extendingfrom the front plate to the back plate to fluidly couple the front platefluid opening and the back plate fluid opening which receives an end ofa membrane cartridge at the front plate and is in fluid communicationwith a fluid reservoir adjacent the back plate, the front plate and backplate comprising discrete structural bodies joined together by the atleast one tube to form the permeate adapter; and a tubular sleeve inwhich the front plate, back plate, and at least one tube are received,the tubular sleeve sealingly coupled to the front plate and to the backplate.
 2. The permeate adapter of claim 1, wherein the front platecomprises a front steel end-plate, and wherein the back plate comprisesa back steel end-plate.
 3. The permeate adapter of claim 2, wherein thefront steel end-plate comprises a front notch formed along an outer edgeof the front steel-end plate, and wherein the back steel end-platecomprise a back notch formed along an outer edge of the back steel-endplate.
 4. The permeate adapter of claim 3, wherein the front steelend-plate comprises a front o-ring inserted in the front notch toprovide isolation between the permeate adapter and a membrane cartridgechamber, the front o-ring sealingly compressed between the front steelend-plate and an inner surface of the tubular sleeve.
 5. The permeateadapter of claim 3, wherein the back steel end-plate comprises a backo-ring inserted in the back notch and sealingly compressed between theback steel end-plate and an inner surface of the tubular sleeve.
 6. Thepermeate adapter of claim 1, wherein the at least one tube is selectedfrom the group consisting of a steel, composite, and ceramic pipe. 7.The permeate adapter of claim 1, wherein said permeate adapter isdisposed within a sleeve.
 8. The permeate adapter of claim 1 whereinsaid sleeve comprises permeate exit openings.